A dynamic control method for warehousing and de-warehousing of a photovoltaic module curing buffer device

Abstract

The application discloses a kind of photovoltaic module solidification buffer equipment warehousing and delivery dynamic control method, equipment includes buffer unit, loading / unloading lifting conveyor and buffer conveyor;Buffer unit contains N storage frame, storage frame is equipped with M layer band avoiding notch support rod, the third conveying module of buffer conveyor can avoid notch lifting material.The control method determines the task priority according to the buffer unit occupancy rate: low inventory priority warehousing, high inventory priority delivery, medium inventory executes according to instruction sequence;Buffer conveyor idle module can seamlessly switch tasks when warehousing / delivery.At the same time, through multi-objective optimization model (with conveying speed, layer distribution as variable, optimize time, energy consumption, occupancy balance) and discrete event simulation collaborative control, if condition is not met, use ant colony algorithm to solve iteratively, it can also deal with failure and defect material exclusion, realize efficient and stable control.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic module production technology, and in particular relates to a dynamic control method for the entry and exit of photovoltaic module curing and buffering equipment. Background Technology

[0002] Photovoltaic modules undergo a curing process during production, typically requiring 4 hours of curing at room temperature. The curing temperature and humidity are generally 25℃±2℃ and 65-90% relative humidity. Therefore, a curing chamber is usually set up to maintain constant temperature and humidity conditions for curing the photovoltaic modules. Consequently, it is necessary to have racks capable of holding large numbers of photovoltaic modules and automated loading and unloading devices.

[0003] In the prior art, Chinese Patent Publication No. CN222939890U discloses a highly versatile photovoltaic module buffering device, which includes a buffer bin, a feeding and lifting conveyor, a discharging and lifting device, and a buffer conveying device. It mainly utilizes the lifting and horizontal telescopic movement of the buffer conveying device, together with the feeding and lifting conveyor and the discharging and lifting device, to form a continuous conveying channel through the buffer bin at the target buffering height. This conveying channel is used to transport materials from the feeding and lifting conveyor to the buffer bin for feeding and buffering, or to transport materials from the buffer bin to the discharging and lifting device for discharging and output. However, this buffering device has the following problems in actual use:

[0004] (1) The buffer device only discloses the control flow when the two processes of feeding and unloading are operated independently. If the time period when the material enters the buffer chamber for buffering is different from the time period when the material leaves the buffer chamber, the above control flow can be satisfied. However, when the material enters the warehouse and the material leaves the warehouse at the same time, and the target buffer layer for material entering the warehouse is different from the target unloading layer for material leaving the warehouse, the above control flow cannot be satisfied, and feeding congestion is likely to occur.

[0005] (2) When the buffer bin reaches a high inventory state, and when the material arrival speed is greater than the material discharge speed, the buffer bin's capacity cannot cope with the buffer pressure caused by the difference between the material arrival speed and the discharge speed. If the above control process continues, the buffer bin will easily become fully loaded, causing subsequent components to be unable to enter.

[0006] (3) When one or more materials in the input buffer are defective, if they continue to exist in the buffer, it will waste the storage space of the buffer and also perform invalid operations on the defective component, wasting time and energy. The above-mentioned equipment cannot handle this situation.

[0007] Therefore, it is necessary to provide a dynamic control method for the entry and exit of photovoltaic module solidification and caching equipment to solve the above-mentioned technical problems. Summary of the Invention

[0008] The main objective of this invention is to provide a dynamic control method for the inbound and outbound processes of photovoltaic module solidification and caching equipment. This method effectively solves the problems of unsmooth material transportation, low turnover efficiency, unstable operation, and disruption of production continuity caused by equipment motion interference, poor inventory status adaptability, low task switching efficiency, and insufficient ability to cope with complex scenarios (high load / fault / defective materials) during the operation of photovoltaic module solidification and caching equipment.

[0009] This invention achieves the above objective through the following technical solution: a dynamic control method for the inbound and outbound storage of a photovoltaic module curing and buffering device, wherein the photovoltaic module curing and buffering device comprises:

[0010] The buffer unit includes N storage boxes arranged along the X direction, and each storage box is provided with M vertically distributed buffer layers; N is greater than or equal to 2, and M is greater than or equal to 2.

[0011] The feeding and lifting conveying device is located on the input side of the buffer unit and includes a first conveying module that moves up and down;

[0012] The material feeding and lifting conveying device is located on the output side of the buffer unit and includes a second conveying module that moves up and down.

[0013] A buffer conveying device is provided with N storage boxes in corresponding positions. Each buffer conveying device includes a first lifting conveying mechanism and a second lifting conveying mechanism arranged opposite each other on both sides of the storage box along the Y direction. Both the first lifting conveying mechanism and the second lifting conveying mechanism include a third conveying module that can move up and down and extend and retract in the Y direction.

[0014] The dynamic control method for the inbound and outbound storage of the photovoltaic module solidification and buffering equipment includes:

[0015] When performing material warehousing and caching tasks, material warehousing is prioritized from the bottom layer. If there is a material outgoing and unloading task at the same time, it starts from the Nth warehousing conveyor in the reverse direction along X. Whenever the third conveying module in the warehousing conveyor caches the material into the corresponding storage box, it directly moves up and down to the target outgoing layer to perform the material outgoing and unloading task.

[0016] When performing the material outbound unloading task, if there is a material inbound buffer task at the same time, starting from the first buffer conveyor along the X direction, whenever the third conveyor module in the buffer conveyor outputs the material on the corresponding storage box, it will directly rise and fall to the target buffer layer to perform the material inbound buffer task.

[0017] When the occupancy rate of the cache unit reaches the first set ratio, the material warehousing cache task will be executed first.

[0018] When the occupancy rate of the buffer unit reaches the second set ratio, the material outbound and unloading task is executed first, and the second set ratio is greater than the first set ratio.

[0019] Furthermore, it includes:

[0020] S1. Detect the current occupancy rate of the cache unit. If the occupancy rate reaches the first set ratio, first determine whether there is a material inbound cache task. If there is, execute steps S2 to S5. If not, then determine whether there is a material outbound unloading task. If there is, execute steps S6 to S8. If not, do not take any action.

[0021] S2. The first conveying module in the feeding and lifting conveying device lifts and lowers the plate-shaped material to a set height above the target buffer layer. At the same time, the third conveying module in all buffer conveying devices lifts and lowers to the same height as the first conveying module and extends in the Y direction to be flush with the first conveying module.

[0022] S3. The first conveying module and the third conveying module work together to convey the plate-shaped material to the Nth storage box position. The third conveying module in the Nth buffer conveying device moves downward to place the plate-shaped material on the buffer layer of the Nth storage box, completing the material storage and buffering of the Nth storage box in the target buffer layer. The third conveying module in the Nth buffer conveying device retracts in the Y direction. The first conveying module in the feeding and lifting conveying device descends to the initial height position to receive the next plate-shaped material and lifts it to the set height above the target buffer layer. This process is repeated to realize the feeding of plate-shaped materials.

[0023] S4. Determine if there is a material outbound unloading task. If not, the third conveying module in the Nth buffer conveying device is raised and lowered to the initial height position, waiting for the next instruction. If there is, the third conveying module in the Nth buffer conveying device is raised and lowered directly to the set height below the target outbound layer, extends in the Y direction, and then moves upward to lift the plate-shaped material on the Nth storage box in the target outbound layer. Then, the plate-shaped material on the Nth storage box in the target outbound layer is output along the X direction to realize the outbound unloading.

[0024] S5. Repeat steps S3 to S4 to sequentially complete the warehousing and caching of plate-shaped materials on the N-1, N-2, ..., 1st storage boxes in the target cache layer; if a material outbound task exists simultaneously in the target outbound layer during the time interval of executing the material warehousing and caching task in the target cache layer, then sequentially complete the outbound and unloading of plate-shaped materials on the N-1, N-2, ..., 1st storage boxes in the target outbound layer.

[0025] S6. The second conveying module in the material feeding and lifting conveyor is raised to a set height above the target outgoing layer; the third conveying module in all buffer conveyors is raised to a set height below the target outgoing layer and extends in the Y direction, then moves upward to lift the plate-shaped materials on the N storage boxes to the height where they dock with the second conveying module. The N plate-shaped materials move gradually along the X direction according to the set step distance. When it moves one step distance, the third conveying module in the first buffer conveyor is idle. When it moves two step distances, the third conveying module in the second buffer conveyor is idle, and so on.

[0026] S7. Whenever a third conveyor module becomes available, it is determined whether there is a material warehousing and buffering task. If so, the available third conveyor module is raised and lowered to a set height above the target buffer layer and extends in the Y direction to receive the plate-shaped material conveyed by the first conveyor module in the feeding and lifting conveyor device. Then it moves downward to place the newly arrived plate-shaped material on the target buffer layer of the corresponding storage frame. If not, the available third conveyor module is raised and lowered to the initial height position and waits for the next instruction.

[0027] S8. Repeat steps S6 to S7 to sequentially complete the outbound material feeding of the plate-shaped materials on the Nth, N-1th, ..., 1st storage boxes in the target outbound layer; if there is a material inbound caching task in the target cache layer at the same time during the material outbound task execution period in the target outbound layer, then sequentially complete the inbound caching of the plate-shaped materials on the Nth, N-1th, ..., 1st storage boxes in the target cache layer.

[0028] Furthermore, it includes:

[0029] S1. Detect the current occupancy rate of the cache unit. If the occupancy rate reaches the second set ratio, first determine whether there is a material outbound unloading task. If there is, execute steps S2 to S4. If not, then determine whether there is a material inbound cache task. If there is, execute steps S5 to S8. If not, do nothing.

[0030] S2. The second conveying module in the material feeding and lifting conveyor is raised to a set height above the target outgoing layer; the third conveying module in all buffer conveyors is raised to a set height below the target outgoing layer and extends in the Y direction, then moves upward to lift the plate-shaped materials on the N storage boxes to the height where they dock with the second conveying module. The N plate-shaped materials move gradually along the X direction according to the set step distance. When it moves one step distance, the third conveying module in the first buffer conveyor is idle. When it moves two step distances, the third conveying module in the second buffer conveyor is idle, and so on.

[0031] S3. Whenever a third conveyor module becomes available, it is determined whether there is a material warehousing and buffering task. If so, the available third conveyor module is raised and lowered to a set height above the target buffer layer and extends in the Y direction to receive the plate-shaped material conveyed by the first conveyor module in the feeding and lifting conveyor device. Then it moves downward to place the newly arrived plate-shaped material on the target buffer layer of the corresponding storage frame. If not, the available third conveyor module is raised and lowered to the initial height position and waits for the next instruction.

[0032] S4. Repeat steps S2 to S3 to sequentially complete the outbound material feeding of the plate-shaped materials on the Nth, N-1th, ..., 1st storage boxes in the target outbound layer; if there is a material inbound buffering task in the target buffer layer at the same time during the material outbound task execution period in the target outbound layer, then sequentially complete the inbound buffering of the plate-shaped materials on the Nth, N-1th, ..., 1st storage boxes in the target buffer layer.

[0033] S5. The first conveying module in the feeding and lifting conveying device lifts and lowers the plate-shaped material to a set height above the target buffer layer. At the same time, the third conveying module in all buffer conveying devices lifts and lowers to the same height as the first conveying module and extends in the Y direction to be flush with the first conveying module.

[0034] S6. The first conveying module and the third conveying module work together to convey the plate-shaped material to the Nth storage box position. The third conveying module in the Nth buffer conveying device moves downward to place the plate-shaped material on the buffer layer of the Nth storage box, completing the material storage and buffering of the Nth storage box in the target buffer layer. The third conveying module in the Nth buffer conveying device retracts in the Y direction. The first conveying module in the feeding and lifting conveying device descends to the initial height position to receive the next plate-shaped material and lifts it to the set height above the target buffer layer. This process is repeated to realize the feeding of plate-shaped materials.

[0035] S7. Determine if there is a material outbound unloading task. If not, the third conveying module in the Nth buffer conveying device is raised and lowered to the initial height position, waiting for the next instruction. If there is, the third conveying module in the Nth buffer conveying device is raised and lowered directly to the set height below the target outbound layer, extends in the Y direction, and then moves upward to lift the plate-shaped material on the Nth storage box in the target outbound layer. Then, the plate-shaped material on the Nth storage box in the target outbound layer is output along the X direction to realize the outbound unloading.

[0036] S8. Repeat steps S6 to S7 to sequentially complete the warehousing and caching of plate-shaped materials on the N-1, N-2, ..., 1st storage boxes in the target cache layer; if a material outbound task exists simultaneously in the target outbound layer during the time interval of executing the material warehousing and caching task in the target cache layer, then sequentially complete the outbound and unloading of plate-shaped materials on the N-1, N-2, ..., 1st storage boxes in the target outbound layer.

[0037] Furthermore, when the occupancy rate of the buffer unit reaches the second set ratio and the material outbound unloading task is executed first, the lifting speed of the second conveying module in the unloading lifting conveying device is increased by 1.2 to 1.8 times, or / and the conveying speed of the second conveying module is increased by 1.2 to 1.8 times.

[0038] Furthermore, when the occupancy rate of the buffer unit reaches the second set ratio and the material outbound unloading task is executed first, the conveying speed of the third conveying module in the buffer conveying device is increased by 1.2 to 1.8 times.

[0039] Furthermore, it also includes:

[0040] When the occupancy rate of the cache unit is between the first set ratio and the second set ratio, the corresponding tasks are executed in the order of the material outbound unloading task and the material inbound cache task.

[0041] Furthermore, it also includes:

[0042] When defective materials are found among the N plate-shaped materials entering the target buffer layer, a defective material removal task is executed, which includes the following steps:

[0043] S201. Before the defective material arrives, the third conveying module in all buffer conveying devices is raised to a set height above the target buffer layer and extends in the Y direction; at the same time, the second conveying module in the unloading lifting conveying device is raised to a set height above the target buffer layer and is flush with the rightmost third conveying module.

[0044] S202, the first conveying module in the feeding and lifting conveying device lifts and lowers the defective material to a set height above the target buffer layer and is flush with the third conveying module on the far left.

[0045] S203, the first conveying module, the second conveying module, and the third conveying module work together to directly convey the defective material along the X direction to the second conveying module in the unloading lifting conveyor. Then, the second conveying module descends to the unloading height and outputs the defective material to the subsequent manual picking position or directly to the defective product output position.

[0046] Furthermore, including:

[0047] The system acquires the operating status data and task request queue of the photovoltaic module caching device. The operating status data includes the occupancy rate of the caching unit, the layer distribution information of the storage box, and the real-time position and speed parameters of the conveying device. The task request queue includes the priority order of material inbound caching tasks and material outbound unloading tasks. The conveying device includes a feeding lifting conveying device, a caching conveying device, and an unloading lifting conveying device.

[0048] A multi-objective optimization model is generated based on the operating status data and task request queue. The multi-objective optimization model includes an optimization objective function and constraints. The optimization objective function uses the lifting speed of the conveying device, the conveying speed, and the layer allocation of the storage box as decision variables. The constraints include the avoidance relationship of the conveying path in the conveying device, the capacity limit of the storage box, and the movement range limit of the conveying device.

[0049] The operational status data is simulated and analyzed using a discrete event simulation model, and the output shows the trend of occupancy rate of the buffer unit, the time distribution of material entry and exit, and the energy consumption distribution of the buffer conveying device.

[0050] When the occupancy rate of the buffer unit meets the set conditions, the operating parameters of the buffer conveying device are updated according to the corresponding decision variables and the material in / out task is executed; otherwise, the ant colony algorithm module is used to solve the multi-objective optimization model to generate new decision variables until the occupancy rate of the buffer unit meets the set conditions.

[0051] Furthermore, the ant colony optimization module is used to solve the multi-objective optimization model to generate new decision variables, including:

[0052] Initialize the initial solution set of the ant colony algorithm. The initial solution set contains multiple candidate solutions, and each candidate solution corresponds to a set of lifting speed, conveying speed and storage box layer allocation scheme of the conveying device.

[0053] The candidate solutions in the initial solution set are simulated using a discrete event simulation model to obtain the corresponding buffer unit occupancy rate, material inbound and outbound time, and energy consumption index of the buffer conveying device.

[0054] The overall performance score for each candidate solution is calculated based on the above indicators;

[0055] Candidate solutions are sorted according to their comprehensive performance scores, and the solution set is updated according to the iterative mechanism of the ant colony algorithm.

[0056] Repeat the above steps until the preset convergence condition or the maximum number of iterations is reached, and output the optimal solution;

[0057] The corresponding operating parameters of the buffer conveying device and the layer allocation scheme of the storage box are determined based on the optimal solution.

[0058] Furthermore, before obtaining the operating status data and task request queue of the photovoltaic module caching device, the following steps are also included:

[0059] The range of variation of structural and operational parameters of the photovoltaic module caching device is obtained. The structural parameters include the number of storage frames and the number of support layers. The operational parameters include the lifting speed range of the conveying device, the conveying speed range, and the layer allocation strategy of the storage frames.

[0060] A discrete event simulation model is established based on the variation range of the structural parameters and operating parameters, and the distribution of the support rods of the storage box in the discrete event simulation model is configured.

[0061] Compared with the prior art, the beneficial effects of the present invention's dynamic control method for the inbound and outbound storage of a photovoltaic module curing and caching device are as follows:

[0062] (1) The support rod is designed with an open structure to avoid gaps, which, together with the flat design of the third conveying module of the buffer conveying device, allows it to flexibly pass through the gap of the support rod to complete the material lifting and transfer, avoiding interference with the movement of the equipment; the layered support rods of the storage frame work together with multiple conveying devices to maximize space utilization and meet the efficient storage and conveying needs of M layers and N materials at the same time.

[0063] (2) The priority of inbound / outbound is dynamically adjusted according to the occupancy rate of the buffer unit (low / medium / high inventory). Low inventory is given priority for inbound to prevent material shortage, and high inventory is given priority for outbound to prevent material blockage. During the inbound / outbound process, the idle module of the buffer conveyor can seamlessly switch tasks (such as directly executing outbound after inbound and directly executing inbound after outbound), reducing equipment idle time and maximizing material turnover efficiency.

[0064] (3) By linking the multi-objective optimization model (using delivery speed and layer allocation as variables to optimize time, energy consumption and occupancy balance) with the discrete event simulation model, the feasibility of the decision is verified in advance; when the conditions are not met, the optimal solution is solved iteratively by the ant colony algorithm, and the buffer occupancy fluctuation is strictly controlled under high load scenarios to reduce the risk of equipment failure and ensure stable operation.

[0065] (4) It can quickly respond to sudden failures (such as abnormal conveying devices or defects in the support rod layer), automatically adjust the task priority and regenerate the optimization model; for defective materials, it can directly convey them to the defective grade through the collaboration of multiple conveying modules, avoid affecting the normal production process, meet the core requirements of "no material blockage and no material shortage" in photovoltaic module production, and improve production continuity. Attached Figure Description

[0066] Figure 1 This is a three-dimensional structural diagram of an embodiment of the present invention;

[0067] Figure 2This is a schematic diagram of the structure of the storage box and the buffer conveying device in an embodiment of the present invention;

[0068] Figure 3 This is a partial structural diagram of the storage frame in an embodiment of the present invention;

[0069] Figure 4 This is a three-dimensional structural diagram of the feeding, lifting, and conveying device in an embodiment of the present invention;

[0070] Figure 5 This is a three-dimensional structural diagram of the material feeding and lifting conveying device in an embodiment of the present invention;

[0071] Figure 6 This is a schematic diagram of the structure of the first lifting and conveying mechanism in an embodiment of the present invention;

[0072] The numbers in the image represent:

[0073] 100 - Photovoltaic module curing and buffering equipment; 200 - Plate-shaped materials;

[0074] 1-Buffer unit, 11-Storage box, 111-Bearing rod, 1111-First support rod, 1112-Second support rod, 112-Avoidance notch, 113-Support column;

[0075] 2-Feeding and lifting conveyor device, 21-Fourth driving component, 22-First support, 23-First conveying module, 24-First stop module;

[0076] 3-Discharge lifting and conveying device, 31-Fifth driving component, 32-Second support, 33-Second conveying module, 34-Second stop module;

[0077] 4-Buffer conveying device, 41-First lifting and conveying mechanism, 411-First driving component, 412-Lifting plate, 413-Second driving component, 414-Mounting plate, 415-Third conveying module, 42-Second lifting and conveying mechanism. Detailed Implementation

[0078] Please refer to Figures 1-6 This embodiment is a photovoltaic module curing and buffering device 100, which includes a buffer unit 1, a feeding lifting and conveying device 2 disposed on the input side of the buffer unit 1, a discharging lifting and conveying device 3 disposed on the output side of the buffer unit 1, and a buffer conveying device 4 that conveys the plate-shaped material 200 on the feeding lifting and conveying device 2 into the buffer unit 1 or conveys the plate-shaped material 200 in the buffer unit 1 to the discharging lifting and conveying device 3.

[0079] The buffer unit 1 includes N storage boxes 11 arranged in a docking manner along the X direction, and each storage box 11 is provided with M layers of vertically distributed support rods 111.

[0080] The feeding and lifting conveying device 2 includes a fourth driving component 21, a first support 22 driven by the fourth driving component 21 to move up and down, and a first conveying module 23 disposed on the first support 22 and conveying materials in the X direction. A first stop module 24 is disposed on the first support 22 at the end of the first conveying module 23.

[0081] The material feeding and lifting conveying device 3 includes a fifth driving member 31, a second support 32 driven by the fifth driving member 31 to move up and down, and a second conveying module 33 disposed on the second support 32 and conveying materials in the X direction. A second stop module 34 is disposed on the second support 32 at the end of the second conveying module 33.

[0082] N buffer conveying devices 4 are provided, each corresponding to one of the N storage boxes 11. Each buffer conveying device 4 includes a first lifting conveying mechanism 41 and a second lifting conveying mechanism 42 arranged opposite each other on both sides of the storage box 11 along the Y direction. The first lifting conveying mechanism 41 and the second lifting conveying mechanism 42 have the same structure and both include a first driving member 411, a lifting plate 412 driven by the first driving member 411 to move up and down, a second driving member 413 fixed on the lifting plate 412, a mounting plate 414 driven by the second driving member 413 to move telescopically along the Y direction, and a third conveying module 415 arranged on the mounting plate 414 and conveying materials along the X direction. The module of the third conveying module 415 used to carry materials and realize conveying has a flat structure, and the sum of the height of the flat structure and the height of the material is less than the distance between two adjacent upper and lower support rods 111, so that the third conveying module 415 can easily extend between two adjacent upper and lower support rods 111 and lift materials into or out of the storage.

[0083] The first lifting conveyor mechanism 41 and the second lifting conveyor mechanism 42 work together to support the bottom of the plate-shaped material 200 on both sides in the Y direction through two third conveyor modules 415. When it is necessary to convey the plate-shaped material 200 on a certain layer support rod 111, the first lifting conveyor mechanism 41 and the second lifting conveyor mechanism 42 simultaneously lift the corresponding third conveyor module 415 to below the layer support rod 111, and then move upward to above the layer support rod 111, lifting the plate-shaped material 200 on the layer support rod 111 and conveying it out, thus realizing material output. When it is necessary to buffer the plate-shaped material 200 on a certain layer support rod 111, the first lifting conveyor mechanism 41 and the second lifting conveyor mechanism 42 simultaneously lift the corresponding third conveyor module 415 to above the layer support rod 111, and after receiving the plate-shaped material 200, lower it to below the layer support rod 111, transferring the plate-shaped material 200 to the layer support rod 111, thus realizing material buffering.

[0084] During the aforementioned material buffering and output process, the third conveying module 415 in both the first lifting conveying mechanism 41 and the second lifting conveying mechanism 42 undergoes a vertical movement between below and above the support rod 111. To achieve this movement, the support rod 111 has undergone structural optimization design in this embodiment. Specifically, the support rod 111 is provided with a clearance notch 112 for the conveying modules in the first and second lifting conveying mechanisms 41 and 42 to pass through vertically. The storage frame 11 also includes a support column 113, with one Y-direction end of the support rod 111 fixed to the support column 113 and the other Y-direction end extending horizontally into the storage frame 11.

[0085] In this embodiment, the support rod 111 includes a first support rod 1111 extending along the X direction and a pair of second support rods 1112 extending along the Y direction from both ends of the first support rod 1111 in the X direction. The first support rod 1111 and the pair of second support rods 1112 together form the clearance notch 112. The side of the clearance notch 112 facing the first lifting and conveying mechanism 41 or the second lifting and conveying mechanism 42 is an open structure. The end of the second support rod 1112 is fixed to the support column 113.

[0086] In other embodiments, the support rod 111 can be a plate-like structure with a clearance notch 112 that opens toward the first lifting conveying mechanism 41 or the second lifting conveying mechanism 42.

[0087] The dynamic control method for material inbound and outbound based on photovoltaic module solidification and caching device 100 determines the priority of material inbound caching and material outbound unloading based on the inventory status of caching unit 1, under the premise of ensuring that "there is no congestion at the material inbound end and no shortage of material at the material outbound end". Check the inventory status of cache unit 1. If the inventory occupancy rate of cache unit 1 reaches the first set ratio (e.g., cache unit 1 occupancy rate is less than or equal to 30%, 40%, or 20%), it is in a low inventory state, and the material inbound cache task is executed first. If the inventory occupancy rate of cache unit 1 reaches the second set ratio (e.g., cache unit 1 occupancy rate is greater than or equal to 70%, 60%, or 80%), it is in a high inventory state, and the material outbound unloading task is executed first. When the inventory occupancy rate of cache unit 1 is between the first set ratio and the second set ratio (e.g., cache unit 1 occupancy rate is greater than 30% and less than 70%, or greater than 40% and less than 60%, or greater than 20% and less than 80%), it is in a medium inventory state, and the corresponding process is executed in sequence according to the instruction requests of the material inbound cache task and the material outbound unloading task.

[0088] In addition, when performing material receiving and caching tasks, material caching is prioritized from the bottom layer. If material receiving and unloading tasks also exist, the process starts from the Nth caching conveyor along the X direction in reverse. Whenever the third conveying module in the caching conveyor caches material into the corresponding storage box, it directly moves up and down to the target receiving layer to perform the material receiving and unloading task. When performing material receiving and unloading tasks, if material receiving and caching tasks also exist, the process starts from the 1st caching conveyor along the X direction. Whenever the third conveying module in the caching conveyor caches material from the corresponding storage box, it directly moves up and down to the target caching layer to perform the material receiving and caching task.

[0089] A dynamic control method for material inbound and outbound operations based on photovoltaic module solidification and caching equipment specifically includes:

[0090] S1. Detect the current occupancy rate of the cache unit. If the occupancy rate reaches the first set ratio (low inventory state), then execute steps S2 to S6 first, and then execute steps S7 to S9. If the occupancy rate reaches the second set ratio (high inventory state), then execute steps S7 to S9 first, and then execute steps S2 to S6. If the occupancy rate is between the first set ratio and the second set ratio (medium inventory state), then execute steps S2 to S6 or steps S7 to S9 according to the order in which the system receives the material inbound cache task and the material outbound unloading task.

[0091] S2. The first conveying module 23 in the feeding and lifting conveying device 2 lifts and lowers the plate-shaped material 200 to a set height above the target buffer layer support rod. At the same time, the third conveying modules 415 in all the buffer conveying devices 4 lift and lower to the same height position as the first conveying module 23, and extend in the Y direction to be flush with the first conveying module 23. At this time, the first conveying module 23 and all the third conveying modules 415 together form a conveying channel that continuously conveys materials in the X direction and runs through the buffer unit 1.

[0092] S3, the first conveying module 23 and the third conveying module 415 work together to convey the plate material 200 to the position of the Nth storage box 11. The third conveying module 415 in the Nth buffer conveying device 4 moves downward to place the plate material 200 on the support rod 111 of the Nth storage box 11, completing the material storage and buffering of the Nth storage box 11 in the target buffer layer. The third conveying module 415 in the Nth buffer conveying device 4 retracts in the Y direction.

[0093] S4. The first conveying module 23 in the feeding and lifting conveying device 2 descends to the initial height position to receive the next plate material 200 and lifts it to the set height above the target buffer layer support rod. This process is repeated to realize the feeding of plate material 200.

[0094] S5. The system determines whether a material outbound unloading task has been received. If not, the third conveying module 415 in the Nth buffer conveying device 4 is raised and lowered to the initial height position, waiting for the next instruction. If so, the third conveying module 415 in the Nth buffer conveying device 4 is raised and lowered directly to the set height below the target outbound layer support rod, and extends in the Y direction, and then moves upward to lift the plate-shaped material 200 on the Nth storage box 11 in the target outbound layer. At the same time, the second conveying module 33 in the unloading lifting conveying device 3 is raised and lowered to the same height as the third conveying module 415. Then, under the joint action of the third conveying module 415 and the second conveying module 33, the plate-shaped material 200 on the Nth storage box 11 in the target outbound layer is output along the X direction to realize the outbound unloading.

[0095] S6. Repeat steps S3 to S5 to sequentially complete the warehousing and caching of plate-shaped materials 200 on the N-1, N-2, ..., 1st storage boxes 11 in the target cache layer; if a material outbound request instruction exists simultaneously in the target outbound layer during the material warehousing and caching time interval of the target cache layer, then sequentially complete the outbound and unloading of plate-shaped materials 200 on the N-1, N-2, ..., 1st storage boxes 11 in the target outbound layer;

[0096] S7. The second conveying module 33 in the material feeding and lifting conveying device 3 is raised and lowered to a set height above the target outgoing layer; the third conveying module 415 in all buffer conveying devices 4 is raised and lowered to a set height below the target outgoing layer, and extends in the Y direction, and then moves upward to lift the plate-shaped materials on the N storage boxes 11 to the height where they dock with the second conveying module 33. The N plate-shaped materials move gradually along the X direction according to the set step distance. When it moves one step distance, the third conveying module 415 in the first buffer conveying device 4 is idle. When it moves two step distances, the third conveying module 415 in the second buffer conveying device 4 is idle, and so on.

[0097] S8. Whenever a third conveyor module 415 becomes available, it is determined whether there is a material warehousing and buffering task. If so, the available third conveyor module 415 is directly raised and lowered to a set height above the target buffer layer and extends in the Y direction to receive the plate-shaped material 200 conveyed by the first conveyor module 23 in the feeding and lifting conveyor device 2. Then it moves downward to place the newly arrived plate-shaped material on the target buffer layer of the corresponding storage frame 11. If not, the available third conveyor module 415 is raised and lowered to the initial height position and waits for the next instruction.

[0098] S9. Repeat steps S7 to S8 to sequentially complete the outbound material feeding of the plate-shaped materials on the Nth, N-1th, ..., 1st storage boxes in the target outbound layer; if there is a material inbound caching task in the target cache layer at the same time during the material outbound task execution period in the target outbound layer, then sequentially complete the inbound caching of the plate-shaped materials on the Nth, N-1th, ..., 1st storage boxes in the target cache layer.

[0099] In this embodiment, the core principle of the optimal control scheme when material inflow and outflow occur simultaneously is to prioritize ensuring "no material blockage and no material shortage." Priority is dynamically adjusted based on the real-time inventory of buffer unit 1 to maximize equipment utilization. When buffer unit 1 is in a low inventory state, the material inbound buffering task is executed first to avoid material shortages in subsequent processes. When it is in a high inventory state, the material outbound unloading task is executed first to meet unloading (outflow) requirements and avoid material blockage caused by a full buffer bin. Furthermore, when inbound and outbound occur simultaneously, whenever a third conveyor module 415 becomes available in the inbound buffering task, it immediately moves to the target outbound layer to execute the outbound unloading task; whenever a third conveyor module 415 becomes available in the outbound unloading task, it immediately moves to the target buffer layer to execute the inbound buffering task, ensuring seamless connection between inbound and outbound processes and improving inbound and outbound execution efficiency.

[0100] Furthermore, this embodiment also achieves dynamic control of the operating status of the photovoltaic module caching device through the collaborative work of a multi-objective optimization model and a discrete event simulation model. Specifically, this includes:

[0101] First, the acquisition module collects real-time operational status data from the buffer unit 1 and the conveying devices (including the loading lifting conveyor 2, the buffer conveyor 4, and the unloading lifting conveyor 3), and generates a multi-objective optimization model based on the priority order in the task request queue. The operational status data includes the occupancy rate of the buffer unit 1, the layer distribution information of the storage boxes 11, and the real-time position and speed parameters of each conveying module in the conveying devices. This data is transmitted to the optimization module via a sensor network for subsequent analysis and decision-making. The buffer unit 1 consists of multiple storage boxes 11, each with a support rod 111 structure, and the maximum number of support rod layers is M. Each conveying device includes a lifting mechanism and a horizontal conveying module. In actual operation, the lifting speed of the conveying devices is encoded using continuous values, the conveying speed is represented by a piecewise linear function, and the layer allocation of the storage boxes 11 is described using integer encoding.

[0102] After acquiring operational status data, the optimization module generates a multi-objective optimization model based on the data. This model includes an objective function and constraints. The objective function uses the lifting speed of the conveying module, the conveying speed, and the layer allocation of the storage boxes 11 as decision variables. The goal is to achieve comprehensive optimization by minimizing material outbound / inbound time, minimizing energy consumption, and balancing the occupancy rate of the buffer unit 1. Constraints include the avoidance relationship of the conveying path, the capacity limit of the storage boxes 11, and the movement range limit of the conveying device. For example, the avoidance relationship of the conveying path requires the conveying device to avoid interference with other equipment during operation, which is achieved through the size of the avoidance gap 112 and the installation position of the support columns 113. A total of N storage boxes 11 are provided to ensure that each layer of support rods 111 can accommodate N photovoltaic modules. The movement range limit of the conveying device includes the maximum value of the lifting height and the horizontal conveying distance, which are determined by the design specifications of the equipment.

[0103] To verify the practical effect of the multi-objective optimization model, the control module introduces a discrete event simulation model to simulate and analyze the operating status data. The discrete event simulation model dynamically simulates the occupancy rate trend of buffer unit 1, the material outbound / inbound time distribution, and the energy consumption distribution of the conveying device, outputting key performance indicators. If the occupancy rate trend of buffer unit 1 meets the set conditions, the corresponding decision variables are sent to the distributed control system (DCS). The DCS then issues the operating parameters of the conveying device and the layer allocation instructions for storage boxes 11 to the drive module and the operation terminal. The set conditions are determined based on actual production needs, the design capacity of buffer unit 1, and the operating capacity of the conveying device. For example, in high-load scenarios, the set conditions are more stringent, requiring the occupancy rate fluctuation of buffer unit 1 to remain within a small range to ensure the stability of equipment operation.

[0104] If the occupancy rate of buffer unit 1 does not meet the set conditions, the heuristic algorithm module is triggered to solve the multi-objective optimization model. The heuristic algorithm module uses the ant colony algorithm to iteratively optimize the initial solution set. The initial solution set contains multiple candidate solutions, each corresponding to a set of lifting speed, conveying speed, and layer allocation scheme of storage boxes 11. The candidate solutions in the initial solution set are simulated using a discrete event simulation model to obtain the corresponding occupancy rate of buffer unit 1, material in / out time, and energy consumption index of the conveying device. Based on the above indicators, the comprehensive performance score of each candidate solution is calculated, and the candidate solutions are sorted according to the score. Then, the solution set is updated according to the iterative mechanism of the heuristic algorithm, and the above steps are repeated until the preset convergence condition or the maximum number of iterations is reached, and the optimal solution is output. After the optimal solution is determined, its corresponding conveying device operating parameters and storage box 11 layer allocation scheme are sent to the distributed control system DCS8, which executes the specific control instructions.

[0105] In the specific implementation process, the range of variation of the structural and operational parameters of the buffer unit 1 needs to be configured in advance. Structural parameters include the number of storage frames 11, the number of layers of support rods 111, and the geometry of the clearance notch 112; operational parameters include the lifting speed range of each conveying module in each conveying device, the conveying speed range, and the layer allocation strategy of the storage frames 11. These parameters are determined through preliminary modeling and experimental testing, and configured in a discrete event simulation model. For example, the maximum number of layers of support rods 111 in the storage frame 11 is M layers, and the spacing between each layer of support rods 111 is designed according to the thickness of the photovoltaic modules to ensure maximum space utilization while meeting load-bearing capacity requirements. The geometry of the clearance notch 112 is designed according to the movement trajectory of the conveying device to avoid interference during equipment operation.

[0106] Furthermore, this embodiment also considers dynamic control under sudden failure scenarios. When the conveying device malfunctions or a defect occurs in a certain layer of the storage box 11, the system automatically adjusts the priority order of the task request queue and regenerates the multi-objective optimization model. During this process, the discrete event simulation model simulates and analyzes the new operating status data, outputting the adjusted trend of the occupancy rate of the buffer unit 1 and the distribution of material entry and exit times. In this way, the system can respond quickly under high load or sudden failure scenarios, shorten the material entry and exit time, and improve the operating efficiency of the equipment. Specifically, when there are defective materials among the N plate-shaped materials entering the target buffer layer, the defective material removal task is executed, which includes the following steps:

[0107] S201. Before the defective material arrives, the third conveying module 415 in all buffer conveying devices 4 is raised to a set height above the target buffer layer and extends in the Y direction; at the same time, the second conveying module 33 in the unloading lifting conveying device 3 is raised to a set height above the target buffer layer and is flush with the rightmost third conveying module 415.

[0108] S202, the first conveying module 23 in the feeding and lifting conveying device 2 carries the defective material up and down to a set height above the target buffer layer and is flush with the leftmost third conveying module 415.

[0109] S203, the first conveying module 23, the second conveying module 33, and the third conveying module 415 work together to directly convey the defective material along the X direction to the second conveying module 33 in the unloading lifting conveying device 3. Then, the second conveying module 33 descends to the unloading height and outputs the defective material to the subsequent manual picking position or directly to the defective product output position.

[0110] The entire system operates as follows: First, the acquisition module collects operational status data from buffer unit 1 and the conveying device, and generates a multi-objective optimization model based on the task request queue. The optimization module generates decision variables based on the model and verifies its actual effect through a discrete event simulation model. If the occupancy rate of buffer unit 1 meets the set conditions, the decision variables are sent to the distributed control system (DCS) for execution. Otherwise, the heuristic algorithm module solves the model, generates new decision variables, and verifies them again. Finally, the system, through the DCS, sends the optimized operating parameters and layer allocation instructions to the drive module and the operation terminal to complete the material inbound or outbound tasks.

[0111] As can be seen from the above embodiments, this invention achieves global dynamic joint optimization control of the lifting speed, conveying speed, and layer allocation of the storage box 11 in the photovoltaic module buffering equipment conveying device by constructing a multi-objective optimization and discrete event simulation collaborative mechanism. This method not only improves the utilization rate of the storage box 11 and the collaborative efficiency of the conveying device, but also achieves adaptive regulation under high load or sudden failure scenarios, providing a highly efficient and stable control method for photovoltaic module buffering equipment.

[0112] The above descriptions are merely some embodiments of the present invention. Those skilled in the art can make various modifications and improvements without departing from the inventive concept of the present invention, and these all fall within the scope of protection of the present invention.

Claims

1. A method for dynamic control of the entry and exit of a curing buffer device for a photovoltaic module, characterized in that, It comprises: When performing the material storage task, the material is stored from the bottom first; if there is a material unloading task at the same time, the Nth cache conveying device is started along the X reverse direction, and whenever the third conveying module in the cache conveying device stores the material into the corresponding storage frame, it is directly lifted to the target unloading layer to perform the material unloading task; When performing the material unloading task, if there is a material storage task at the same time, the first cache conveying device is started along the X direction, and whenever the third conveying module in the cache conveying device outputs the material on the corresponding storage frame, it is directly lifted to the target storage layer to perform the material storage task; When the occupancy rate of the cache unit reaches the first set proportion, the material storage task is preferentially performed; When the occupancy rate of the cache unit reaches the second set proportion, the material unloading task is preferentially performed, and the second set proportion is greater than the first set proportion; It also comprises: S1, detect the occupancy rate of the current cache unit, if the occupancy rate reaches the first set proportion, first determine whether there is a material storage task, if there is, perform steps S2-S5, if not, then determine whether there is a material unloading task, if there is, perform steps S6-S8, if not, do nothing; S2, the first conveying module in the feeding lifting conveying device is lifted to a set height above the target cache layer, at the same time, the third conveying module in all cache conveying devices is lifted to the same height position as the first conveying module, and is extended horizontally to be flush with the first conveying module; S3, the first conveying module and the third conveying module jointly act to convey the plate-shaped material to the Nth storage frame position, the third conveying module in the Nth cache conveying device moves downward to place the plate-shaped material on the cache layer of the Nth storage frame, completing the material storage in the Nth storage frame of the target cache layer, the third conveying module in the Nth cache conveying device is retracted horizontally; the first conveying module in the feeding lifting conveying device is lowered to the initial height position to receive the next plate-shaped material and is lifted to the set height above the target cache layer, and the process is repeated to realize the feeding of the plate-shaped material; S4, determine whether there is a material unloading task, if not, the third conveying module in the Nth cache conveying device is lifted to the initial height position to wait for the next instruction; if there is, the third conveying module in the Nth cache conveying device is directly lifted to a set height below the target unloading layer and is extended horizontally, then moves upward to lift the plate-shaped material in the Nth storage frame of the target unloading layer, and then outputs the plate-shaped material in the Nth storage frame of the target unloading layer along the X direction to realize the unloading; S5, repeat steps S3-S4 to sequentially complete the storage of the plate-shaped material in the N-1th, N-2th, …, 1st storage frame of the target cache layer; if there is a material unloading task in the target unloading layer during the time period of performing the material storage task in the target cache layer, sequentially complete the unloading of the plate-shaped material in the N-1th, N-2th, …, 1st storage frame of the target unloading layer. S6, the second conveying module in the unloading lifting conveying device is lifted to a set height above the target delivery layer; the third conveying module in all buffer conveying devices is lifted to a set height below the target delivery layer, and is extended in the Y direction, and then moves upward to hold the N plate-shaped materials on the storage frames upward to a height that is in abutment with the second conveying module, and the N plate-shaped materials are moved gradually in the X direction according to a set step distance, when one step distance is moved, the third conveying module in the first buffer conveying device is idle, when two step distances are moved, the third conveying module in the second buffer conveying device is idle, and so on; S7, whenever a third conveying module is idle, it is determined whether there is a material storage buffer task, if yes, the idle third conveying module is directly lifted to a set height above the target buffer layer, and is extended in the Y direction to receive the plate-shaped materials conveyed by the first conveying module in the material loading lifting conveying device, and then moves downward to place the newly incoming plate-shaped materials on the target buffer layer of the corresponding storage frame; if not, the idle third conveying module is lifted to an initial height position, and waits for the next instruction; S8, steps S6-S7 are repeated to sequentially complete the delivery and unloading of the plate-shaped materials on the Nth, N-1th,..., 1st storage frames in the target delivery layer; if there is a material storage buffer task of the target buffer layer within the time section of the material delivery and unloading task of the target delivery layer, the material storage buffer task of the plate-shaped materials on the Nth, N-1th,..., 1st storage frames in the target buffer layer is sequentially completed.

2. The delivery and unloading dynamic control method of the photovoltaic module curing buffer device according to claim 1, characterized in that, in step S1, if the occupancy rate reaches the second set proportion, it is first determined whether there is a material delivery and unloading task, if yes, steps S6-S8 are executed; if not, it is further determined whether there is a material storage buffer task, if yes, steps S2-S5 are executed, if not, no action is taken.

3. The method of claim 1, wherein the method further comprises: determining whether the photovoltaic module curing buffer device is empty; and if the photovoltaic module curing buffer device is empty, moving the photovoltaic module curing buffer device to the second location. When the occupancy rate of the buffer unit reaches the second set proportion and the material delivery and unloading task is preferentially executed, the lifting speed of the second conveying module in the unloading lifting conveying device is increased by 1.2-1.8 times, or / and the conveying speed of the second conveying module is increased by 1.2-1.8 times.

4. The method of claim 3, wherein the method further comprises: determining whether the photovoltaic module curing buffer device is empty; and if the photovoltaic module curing buffer device is empty, moving the photovoltaic module curing buffer device to the second location. When the occupancy rate of the buffer unit reaches the second set proportion and the material delivery and unloading task is preferentially executed, the conveying speed of the third conveying module in the buffer conveying device is increased by 1.2-1.8 times.

5. The method of claim 1, wherein the method further comprises: determining whether the photovoltaic module curing buffer device is empty; and if the photovoltaic module curing buffer device is empty, moving the photovoltaic module curing buffer device to the second location. Further comprising: When the occupancy rate of the buffer unit is between the first set proportion and the second set proportion, the corresponding task is executed according to the request sequence of the material delivery and unloading task and the material storage buffer task.

6. The method of claim 1, wherein the method further comprises: Further comprising: When there is a defective material in the N plate-shaped materials in the target buffer layer, a defective material exclusion task is executed, which includes the following steps: S201, before the defective material arrives, the third conveying module in all buffer conveying devices is lifted to a set height above the target buffer layer, and is extended in the Y direction; at the same time, the second conveying module in the unloading lifting conveying device is lifted to a set height above the target buffer layer, and is in abutment with the third conveying module on the right side. S202, the first conveying module in the feeding lifting conveying device lifts the defective material to a set height above the target buffer layer and is flushly connected with the leftmost third conveying module; S203, the first conveying module, the second conveying module and the third conveying module jointly act to directly convey the defective material to the second conveying module in the discharging lifting conveying device along the X direction, and then the second conveying module is lowered to a discharging height to output the defective material to a subsequent manual picking position or directly to a defective product output position.

7. The method of claim 1, wherein the method further comprises: determining whether the photovoltaic module curing buffer device is empty; and if the photovoltaic module curing buffer device is empty, then moving the photovoltaic module curing buffer device to a location where the photovoltaic module curing buffer device is not in the path of the photovoltaic module. Comprise: obtain the running state data of the photovoltaic module buffer equipment and the task request queue, wherein the running state data comprises the occupancy rate of the buffer unit, the layer distribution information of the storage frame, the real-time position and speed parameters in the conveying device, and the task request queue comprises the priority sorting of the material warehousing buffer task and the material discharging unloading task; the conveying device comprises a feeding lifting conveying device, a buffer conveying device and a discharging lifting conveying device; generate a multi-objective optimization model according to the running state data and the task request queue, the multi-objective optimization model contains an optimization objective function and a constraint condition, the optimization objective function takes the lifting speed, conveying speed of the conveying device and layer distribution of the storage frame as decision variables, and the constraint condition includes the avoidance relationship of the conveying path in the conveying device, the capacity limit of the storage frame and the motion range limit of the conveying device; simulate and analyze the running state data through a discrete event simulation model, output the occupancy rate change trend of the buffer unit, the material warehousing and discharging time distribution and the energy consumption distribution of the buffer conveying device; when the occupancy rate change trend of the buffer unit meets the set condition, update the running parameters of the buffer conveying device according to the corresponding decision variables and execute the material warehousing and discharging task; otherwise, solve the multi-objective optimization model by using an ant colony algorithm module to generate new decision variables until the occupancy rate change trend of the buffer unit meets the set condition.

8. The method of claim 7, wherein the method further comprises: determining whether the photovoltaic module curing buffer device is empty; and if the photovoltaic module curing buffer device is empty, moving the photovoltaic module curing buffer device to the second location. The method for solving the multi-objective optimization model by using the ant colony algorithm module to generate new decision variables comprises: initialize the initial solution set of the ant colony algorithm, the initial solution set contains multiple candidate solutions, and each candidate solution corresponds to a set of lifting speed, conveying speed of the conveying device and layer distribution scheme of the storage frame; simulate and run the candidate solutions in the initial solution set by using the discrete event simulation model to obtain the corresponding buffer unit occupancy rate, material warehousing and discharging time and buffer conveying device energy consumption index; calculate the comprehensive performance score of each candidate solution based on the above index; sort the candidate solutions according to the comprehensive performance score, and update the solution set according to the iteration mechanism of the ant colony algorithm; repeat the above steps until the preset convergence condition or the maximum iteration number is reached, and output the optimal solution; determine the corresponding buffer conveying device running parameters and storage frame layer distribution scheme according to the optimal solution.

9. The method of claim 7, wherein the method further comprises: determining whether the photovoltaic module curing buffer device is empty; and if the photovoltaic module curing buffer device is empty, moving the photovoltaic module curing buffer device to the second location. Before obtaining the running state data of the photovoltaic module buffer equipment and the task request queue, further comprising: Obtaining a change range of a structure parameter and an operation parameter of a photovoltaic module caching device, wherein the structure parameter comprises a number of storage frames and a number of layers of a supporting rod, and the operation parameter comprises a lifting speed range of a conveying device, a conveying speed range, and a layer position allocation strategy of the storage frame; A discrete event simulation model is established according to the change range of the structure parameter and the operation parameter, and a supporting rod distribution of the storage frame in the discrete event simulation model is configured.

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